Pouch with peelable seal for beverages

ABSTRACT

Packaging containers for liquids, such as beverages, comprise: at least one sidewall comprising an edge seal and a frangible border that intersects the edge seal, the sidewall defining a body and a hood; and a primary insert both surfaces of which are affixed to the body, the primary insert comprising a peelable seal. Upon tearing of the frangible border, the hood is separated from the body. In use, a straw contacts the primary insert and opens the peelable seal which has not been exposed to the environment until the hood is removed.

TECHNICAL FIELD

The present disclosure relates to packaging containers for liquids suchas pouches and boxes that provide sanitary surfaces for receivingstraws. The containers comprise a primary insert affixed to the sidewallof the container, the primary insert comprising a peelable seal.

BACKGROUND

In the art of providing liquid containers, specifically those containersthat use a straw for dispensing/delivery of the liquid such as juice ina pouch or box, certain current state-of-the-art technologies requireinsertion of the straw through a film, which may be difficult dependingon the strength of the film. Some commercial packages rely on primarypackage walls having preformed holes with easily breakable films or withremovable strips in order for the straw to penetrate, but this cancreate risk of failure due to premature puncture. Also, with somecurrent practices, the straw must puncture a surface that may have beenexposed to potentially unsanitary conditions.

There is an on-going need to provide liquid packaging containers such aspouches or boxes that provide excellent protection to and sanitaryconditions for the liquid products such as juice, while at the same timeare economical.

SUMMARY

In order to provide sanitary conditions for receiving a straw and forproviding a resealable container—a pouch, for example, having at leastone sidewall—provided are primary inserts affixed to a body of acontainer, the primary inserts comprising a peelable seal that may beresealed as needed. The container comprises a sidewall defining the bodyand a hood. The sidewall has an edge seal and a frangible border thatintersects the edge seal. Upon tearing of the frangible border, the hoodis separated from the body. In use, a straw contacts the primary insertand opens the peelable seal which has not been exposed to theenvironment with the hood is removed. Thus, a sanitary surface—one thathas not been exposed to the environment during handling—is provided forreceiving a straw. Because there is not a pre-formed opening for thestraw, the receipt by the inner layer of a straw conforms exactly to thestraw being used and the straw fits snugly with the container duringuse. When a pressure sensitive adhesive is provided with the peelableseal, the seal may be resealed.

In an aspect, therefore, provided are packaging containers for liquids,such as beverages, the containers comprising at least one sidewallcomprising an edge seal and a frangible border that intersects the edgeseal, the sidewall defining a body and a hood; and a primary insertaffixed to the body, the primary insert comprising a peelable seal. Upontearing the frangible border, the hood and the body are separated.

Other features that may be used individually or in combination withrespect to any aspect of the invention are as follows.

The sidewall may comprise a first panel and a second panel whose edgesare affixed thereby forming the edge seal. The sidewall may comprise anethylene-vinyl alcohol (“EVOH”) copolymer or a foil film. The packingcontainer may optionally further comprise one or more gussets inconjunction with the panels, the container being formed into a stand-uppouch.

The peelable seal may comprises a strength layer and a delaminationlayer such that upon contact by a straw the delamination layer separatesfrom the strength layer thereby opening the peelable seal. Thedelamination layer may comprise a polymer that is a pressure sensitiveadhesive.

The container may further comprise a secondary insert affixed to onesurface of the primary insert and to the body.

A first surface of the primary insert at a first end towards the hoodmay be affixed to the body and a second surface of the primary insert ata second end away from the hood may be affixed to the body.

A detailed aspect is a packaging container for liquid, the containercomprising a first panel and a second panel whose edges are affixedthereby forming an edge seal; a frangible border along both the firstpanel and the second panel, the frangible seal intersecting the edgeseal; and a primary insert both surfaces of which are affixed to thebody, the primary insert comprising a peelable seal that comprises astrength layer and a delamination layer such that upon contact by astraw the delamination layer separates from the strength layer therebyopening the peelable seal.

In another aspect, provided is a method of a packaging container for aliquid, the method comprising: forming at least one sidewall byextruding a first polymer resin through a die or obtaining a foil film;affixing the primary insert to the sidewall; forming an edge seal byaffixing the edges of the sidewall; and forming a frangible border byscoring the sidewall.

An additional aspect is a method of delivering a liquid product in apackaging container, the method comprising: obtaining any packingcontainer of disclosed herein comprising liquid product therein; tearingthe frangible border; and inserting a straw through the peelable seal.The method may further comprise resealing the peelable seal.

These and other aspects of the invention are described in the detaileddescription below. In no event should the above summary be construed asa limitation on the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments of the disclosurein connection with the accompanying drawings, in which:

FIG. 1 is a schematic view of an exemplary liquid packaging container inthe shape of a pouch;

FIGS. 2A and 2B show cross-section views of an embodiment showing aprimary insert affixed to the body of the container;

FIGS. 3A and 3B show cross-section views of another embodiment showingprimary and secondary inserts affixed to the body of the container; and

FIG. 4 is a cross-section view of an exemplary welding pattern of aprimary insert.

The figures are not necessarily to scale. Like numbers used in thefigures refer to like components. It will be understood, however, thatthe use of a number to refer to a component in a given figure is notintended to limit the component in another figure labeled with the samenumber.

DETAILED DESCRIPTION

Provided are packaging containers for liquids that provide sanitarysurfaces for receiving straws. The containers comprise a primary insertaffixed to a body of the container, the primary insert comprising apeelable seal.

“Peelable seal” and like terminology are used herein to refer to a seal,and especially heat seals, which are engineered to be readily peelablewithout uncontrolled or random tearing or rupturing the packagingmaterials that may result in premature destruction of the package and/orinadvertent contamination or spillage of the contents of the package. Apeelable seal is one that can be manually peeled apart to open thepackage at the seal without resort to a knife or other implement to tearor rupture the package. The force required to affect adhesive orcohesive failure of a delamination layer may be measured by its “peelstrength” in accordance with ASTM F-904 test methods. A delaminationlayer is adapted to remain secure and unbroken during packagefabrication, distribution and storage, and yet may be relatively easilyruptured. Accordingly, the peel strength of a frangible layer is between1000 gram-force/inch (175.1 Newton/meter) and 5000 gram-force/inch(875.5 Newton/meter) as measured in accordance with ASTM F-904 testmethod. An exemplary peelable/resealable packaging film is provided inU.S. Pat. No. 7,422,782, the disclosure of which is incorporated hereinby reference.

A “delamination layer” is one that is structured to peel or delaminateduring use in order to form a peelable seal. That is, such a layerexhibits adhesive failure, i.e., separation or delamination at aninterface from an adjoining layer by application of a pulling or peelingforce, or cohesive failure, i.e., separation within the delaminationlayer by application of a pulling or peeling force.

A “strength layer” is one that maintains its structure and is usuallyused in conjunction with a delamination layer to provide structure oncethe delamination layer has separated or delaminated.

Reference to “frangible” means easily broken.

A “layer” as used herein refers to a building block of sidewalls that isa structure of a single polymer-type or a blend of polymers or that maybe an additive.

Reference to “abuse layer” or “outer layer” as used herein refers to theportion of the container that located outermost of all the layers and issubject to handling and the environment. The abuse layer is exposed tovarying conditions at any given time, some of which may be unsanitary.

Reference to an “inner surface” means the surface of a layer away fromthe outer layer and towards the interior where the liquid is packaged.

An “inner layer” as used herein refers to a layer is that is not exposedto the handling and the environment. An exemplary inner layer is abarrier layer, which provides protection to the packaged liquid forfreshness and/or a barrier to oxygen.

A “sealant layer” is one that seals to itself to form a liquid-tightseal. That is, the sealant layer comprises a thermoplastic polymer orpolymer mixture that softens when exposed to heat and returns to itsoriginal condition when cooled to room temperature.

A “sidewall” is a discrete piece of polymer film or multi-layer laminatethat is sealed to itself or another sidewall by, for example, welding oran adhesive, to form a pouch or a bag.

Insert Materials

An insert structure, e.g., primary and/or secondary insert, is typicallyformed from a multi-layered laminate. In general terms, the primaryinsert comprises at least a strength layer and a delamination layer. Thesecondary insert comprises a strength layer and optionally adelamination layer.

The delamination layer may comprise a polymer that is a pressuresensitive adhesive. The pressure sensitive adhesive may comprise anelastomeric first component and a tackifier second component. Theelastomeric first component may comprise a styrene/rubber copolymerselected from the group consisting of: polystyrene/butadiene/styrene(SBS), polystyrene/isoprene/styrene (SIS),polystyrene/ethylene-butylene/styrene (SEBS), andpolystyrene/ethylene-propylene/styrene (SEPS), or blends of any of thesematerials, and the tackifier second component may comprise a terpeneresin or a petroleum hydrocarbon resin.

The strength layer may comprise a polymer that is a heat-sealable,water-insoluble polyester. The polyester may comprise a homopolymer orcopolymer of an alkyl-aromatic ester, such as, for example, but notlimited to, polyethylene terephthalate (PET), amorphous polyethyleneterephthalate (APET), crystalline polyethylene terephthalate (CPET),glycol-modified polyethylene terephthalate (PETG), and polybutyleneterephthalate; copolymers of terephthalate and isophthalate, such as,for example, but not limited to, polyethylene terephthalate/isophthalatecopolymer; and homopolymers and copolymers of aliphatic esters such as,for example, polylactic acid (PLA) and polyhydroxyalkonates, such as,for example, but not limited to, polyhydroxypropionate,poly(3-hydroxybutyrate) (PH3B), poly(3-hydroxyvalerate) (PH3V),poly(4-hydroxybutyrate) (PH4B), poly(4-hydroxyvalerate) (PH4V),poly(5-hydroxyvalerate) (PH5V), poly(6-hydroxydodecanoate) (PH6D) andblends of any of these materials.

Sidewall Materials

A sidewall is typically formed from a multi-layered laminate. In generalterms, there is at least an abuse layer and an inner layer. In specificterms, there may be an abuse layer, an inner or barrier layer, and asealant layer.

The abuse layer may comprise any suitable polyester. An exemplarypolyester is an oriented polyethylene terephthalate (OPET).

In general, the sealant layer may comprise any suitable thermoplasticmaterial including, but not limited too, synthetic polymers such aspolyesters, polyamides, polyolefins, polystyrenes, and the like.Thermoplastic materials may also include any synthetic polymer that arecross-linked by either radiation or chemical reaction during amanufacturing or post-manufacturing process operation. Exemplarypolyolefins include polyethylene (PE) and polypropylene (PP).

A layer having an ethylene/vinyl alcohol (“EVOH”) copolymer filmprovides oxygen barrier protection and may be suitable in an inner layersuch as a barrier layer. A foil film, such as aluminum foil, alsoprovides oxygen barrier protection and may be suitable alone or incombination with other films in an inner layer such as a barrier layer.

Between any of the layers, an adhesive coating or layer may be providedto provide adhesion and continuity between the layers. Adhesivecompositions invention may include, but Pare not limited to: modifiedand unmodified polyolefins, preferably polyethylene, most preferably,ethylene/α-olefin copolymer, modified and unmodified acrylate resin,preferably selected from the group consisting of ethylene/vinyl acrylatecopolymer, ethylene/ethyl acrylate copolymer, ethylene/butyl acrylatecopolymer, or blends thereof. EVA is an ethylene/vinyl acetateco-polymer, which may be used in particular to form a layer tofacilitate bonding of polymerically dissimilar layers.

Fabrication

In general terms, to form the containers disclosed herein, the followingsteps are used. A desired sidewall is formed by making a single layer ora multi-layered laminate. The sidewall comprises at least one layer thatprovides a barrier such as an ethylene-vinyl alcohol (“EVOH”) copolymeror a foil film. To form a multi-layered laminate, techniques known inthe art may be used. In general terms, there is at least an abuse layerand an inner layer. In specific terms, there may be an abuse layer, aninner or barrier layer, and a sealant layer.

Thus, the sidewall is formed by extruding at least a first polymer resinthrough a die or obtaining a foil film. For multi-layers, multipleresins or prepared films are used and attached to each other. A primaryinsert may be formed in a manner similar to that of the sidewall usingthe desired polymeric ingredients. Both surfaces of the primary insertare affixed to the sidewall—directly or indirectly. Should a secondaryinsert be used, one of its surfaces would be affixed to a surface of theprimary insert and the other of its surfaces would be affixed to thesidewall. An edge seal is formed by affixing, for example, heat sealing,the edges of the sidewall. A frangible border is formed by scoffing thesidewall.

Before describing several exemplary embodiments of the invention, it isto be understood that the invention is not limited to the details ofconstruction or process steps set forth in the following description.The invention is capable of other embodiments and of being practiced orbeing carried out in various ways.

Turning to the figures, FIG. 1 is a schematic view of an exemplaryliquid packaging container 100 in the shape of a pouch. The liquidpackaging container 100 comprises a sidewall 102 that defines a body 126and a hood 118. The sidewall 102 comprises an edge seal 104 and afrangible border 106 that divides the body 126 and the hood 118. Thefrangible border 106 intersects the edge seal 104.

FIGS. 2A and 2B show cross-section views of an embodiment showing aprimary insert 112 affixed to the body of the container. The body inthis embodiment comprises a front/first panel 108 a and a second/backpanel 108 b attached together by the edge seal 104. The hood 118separates from the body at frangible border 106. In FIG. 2A, the hood118 is in place and in FIG. 2B, the hood is removed to show contact ofstraw 110 with the primary insert 112 and opening of the peelable seal114.

FIGS. 3A and 3B show cross-section views of another embodiment showing aprimary insert 112 and a secondary insert 116 affixed to the body of thecontainer. The body in this embodiment comprises a front/first panel 108a and a second/back panel 108 b attached together by the edge seal 104.The hood 118 separates from the body at frangible border 106. In FIG.3A, the hood 118 is in place and in FIG. 3B, the hood is removed to showcontact of straw 110 with the primary insert 112 and the secondaryinsert 116 and opening of the peelable seal 114.

FIG. 4 is a cross-section view of an exemplary welding pattern of aprimary insert 112. The second/back panel 108 b is welded to a firstsurface at a hood-end 128 (e.g., end towards the hood) of the primaryinsert 112. The first/front panel 108 a is welded to a second surface ata bottom-end 130 (e.g., end away from the hood) of the primary insert112. In this way, the straw is guided towards the bottom end of theprimary insert 112 upon contact with it.

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as molecular weight, reaction conditions,and so forth used in the specification and claims are to be understoodas being modified in all instances by the term “about.” Accordingly,unless indicated to the contrary, the numerical parameters set forth inthe following specification and attached claims are approximations thatmay vary depending upon the desired properties sought to be obtained bythe present disclosure. At the very least, and not as an attempt tolimit the application of the doctrine of equivalents to the scope of theclaims, each numerical parameter should at least be construed in lightof the number of reported significant digits and by applying ordinaryrounding techniques.

Reference throughout this specification to “one embodiment,” “certainembodiments,” “one or more embodiments” or “an embodiment” means that aparticular feature, structure, material, or characteristic described inconnection with the embodiment is included in at least one embodiment ofthe invention. Thus, the appearances of the phrases such as “in one ormore embodiments,” “in certain embodiments,” “in one embodiment” or “inan embodiment” in various places throughout this specification are notnecessarily referring to the same embodiment of the invention.Furthermore, the particular features, structures, materials, orcharacteristics may be combined in any suitable manner in one or moreembodiments.

Although the invention herein has been described with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It will be apparent to those skilled in the art thatvarious modifications and variations can be made to the method andapparatus of the present invention without departing from the spirit andscope of the invention. Thus, it is intended that the present inventioninclude modifications and variations that are within the scope of theappended claims and their equivalents.

What is claimed is:
 1. A packaging container for liquid, the containercomprising: at least one sidewall comprising an edge seal and afrangible border that intersects the edge seal, the sidewall defining abody and a hood; and a primary insert affixed to the body, the primaryinsert comprising a peelable seal.
 2. The packaging container of claim1, wherein the sidewall comprises a first panel and a second panel whoseedges are affixed thereby forming the edge seal.
 3. The packagingcontainer of claim 1, wherein the peelable seal comprises a strengthlayer and a delamination layer such that upon contact by a straw thedelamination layer separates from the strength layer thereby opening thepeelable seal.
 4. The packaging container of claim 1, wherein upontearing the frangible border, the hood and the body are separated. 5.The packaging container of any one of claim 1 further comprising asecondary insert affixed to one surface of the primary insert and to thebody.
 6. The packaging container of claim 1, wherein the sidewallcomprises an ethylene-vinyl alcohol (“EVOH”) copolymer or a foil film.7. The packing container of claim 1, further comprising one or moregussets, the container being formed into a stand-up pouch.
 8. Thepackaging container of claim 1, wherein a first surface of the primaryinsert at a first end towards the hood is affixed to the body and asecond surface of the primary insert at a second end away from the hoodis affixed to the body.
 9. The packaging container of claim 3, whereinthe delamination layer comprises a polymer that is a pressure sensitiveadhesive.
 10. A packaging container for liquid, the containercomprising: a first panel and a second panel whose edges are affixedthereby forming an edge seal; a frangible border along both the firstpanel and the second panel, the frangible seal intersecting the edgeseal; and a primary insert both surfaces of which are affixed to thebody, the primary insert comprising a peelable seal that comprises astrength layer and a delamination layer such that upon contact by astraw the delamination layer separates from the strength layer therebyopening the peelable seal.
 11. The packaging container of claim 10,wherein a first surface of the primary insert at a first end towards thehood is affixed to the body and a second surface of the primary insertat a second end away from the hood is affixed to the body.
 12. A methodof making a packaging container for a liquid, the method comprising:forming at least one sidewall by extruding a first polymer resin througha die or obtaining a foil film; affixing a primary insert to thesidewall; forming an edge seal by affixing the edges of the sidewall;and forming a frangible border by scoring the sidewall.
 13. A method ofdelivering a liquid product in a packaging container, the methodcomprising: obtaining the packing container of claim 1 comprising liquidproduct therein; tearing the frangible border; and inserting a strawthrough the peelable seal.
 14. The method of claim 13 further comprisingresealing the peelable seal.